Yamaha · Yamaha four-stroke single (XT/TT/SR 500 1976-)

XT500 / TT500

Library entry covers 1976-1981

22 factory 46 guideline

Published source

Yamaha XT500 Service Manual (Yamaha Motor Co.), Maintenance and Lubrication Chart pp.6-7

Factory service manual. Covers XT500 service manual (Yamaha Motor Co.); chart in km and mi.

Open the source

68 items for a 1981 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Dry sump (separate oil tank)
Oil filtration: Mesh screens / strainers only
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Magneto (incl. magdyno, flywheel magneto)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Single carburetor
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Drum (or band / stirrup)
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1981 Yamaha XT500 / TT500

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

On the road: every 1,000 mi

2 items

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline
Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Fittings and fasteners: tighten before each trip and/or. Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi; lights and signals checked at the same interval

Every 300 mi

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Factory

Manual: Drive chain: check tension and alignment, clean and lube. Factory: Maintenance and lubrication chart pp.6-7

Every 1,000 mi or 6 months

1 item

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline

Every 1,000 mi

5 items

Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter (dry type): clean, replace as required. Factory: Maintenance and lubrication chart pp.6-7: first at 1,000 mi
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: top up, check specific gravity and breather pipe. Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch: check and adjust. Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi
Adjust front drum brake

Brakes

Factory

Manual: Brake system (complete): check, adjust, repair. Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Wheels and tires: check pressure, wear, balance. Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi

Every 2,000 mi

7 items

Change engine oil

Engine

Factory

Manual: Engine oil: replace (warm engine before draining). Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi; SAE 20W/40 SE
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: check and adjust. Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi; cam chain tension adjusted every 3,000 mi, checked at 300 mi
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plug: inspect, clean or replace. Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi
Clean fuel tap filter / sediment bowl

Fuel and air

Factory

Manual: Fuel petcock: clean, flush tank as required. Factory: Maintenance and lubrication chart pp.6-7: first at 300 mi
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor: check operation, adjust. Factory: Maintenance and lubrication chart pp.6-7: first at 1,000 mi
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Brake pedal and change pedal shafts: grease lightly. Factory: Maintenance and lubrication chart pp.6-7
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control and meter cables: lubricate thoroughly. Factory: Maintenance and lubrication chart pp.6-7: first at 1,000 mi; throttle grip and housing greased every 2,000 mi

Every 3,000 mi or 12 months

13 items

Check engine mounting bolts and plates

Engine

Guideline
Clean oil strainers / mesh screens

Engine

Guideline

Often done with every oil change on old machines.
Check throttle cable(s) free play and return

Fuel and air

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 4,000 mi or 12 months

2 items

Replace spark plugs

Engine

Guideline
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 4,000 mi

4 items

Compression test (or leak-down)

Engine

Factory

Manual: Cylinder: check compression. Factory: Maintenance and lubrication chart pp.6-7: first at 2,000 mi
Replace oil filter

Engine

Factory

Manual: Oil filter element and oil strainer: replace and clean. Factory: Maintenance and lubrication chart pp.6-7: first at 300 and 2,000 mi
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Factory

Manual: Ignition timing: check, adjust as required. Factory: Maintenance and lubrication chart pp.6-7: first check at 2,000 mi
Change fork oil

Front end

Factory

Manual: Front forks: drain completely and refill. Factory: Maintenance and lubrication chart pp.6-7: SAE 10W/30 SE motor oil

Every 5,000 mi or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 6,000 mi or 12 months

4 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline

Every 6,000 mi or 2 years

3 items

Check engine breather and oil return

Engine

Guideline
Lubricate and check automatic advance unit

Ignition and electrics

Guideline
Magneto: clean slip ring and pickup brush, check HT lead

Ignition and electrics

Guideline

Every 8,000 mi

4 items

Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings: inspect thoroughly, pack moderately. Factory: Maintenance and lubrication chart pp.6-7
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Rear arm pivot shaft: grease lightly. Factory: Maintenance and lubrication chart pp.6-7
Repack / replace wheel bearings

Wheels and tires

Factory

Manual: Wheel bearings: grease, do not over-pack. Factory: Maintenance and lubrication chart pp.6-7
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Factory

Manual: Speedometer gear housing: inspect, pack moderately. Factory: Maintenance and lubrication chart pp.6-7

Every 10,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 12,000 mi or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 25,000 mi or 10 years

1 item

Magneto overhaul / re-magnetize, replace capacitor

Ignition and electrics

Guideline

Weak spark when hot is the classic symptom. Old capacitors fail with age, not miles.

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

1 item

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.